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202005 RADIUM SHOCK SERVICE

MANUAL
PN XXXXX, REV NC.

2005 RADIUM SHOCK SERVICE MANUAL Page 1 PN 20052132 REV


NC
2005 RADIUM SHOCK SERVICE
MANUAL INDEX
Section Description Page
1 INTRODUCTION 3
2 SETUP, TUNING, PERIODIC MAINTENANCE 3
3 GLOSSARY 4
4 COMPLETE SHOCK LESS HARDWARE 5
5 HARDWARE REMOVAL AND INSTALLATION 5
6 DU BUSHING REMOVAL AND INSTALLATION 6
7 AIR CANISTER 8
8 AIR CANISTER REMOVAL AND SEAL SERVICE 9
9 DAMPING SYSTEM 11
10 TROUBLESHOOTING 12
11 TABLE 1: FASTENER TORRADIUMUE RERADIUMUIREMENTS 13
12 RADIUM SHOCK SERVICE KITS 14

Contact Information

Answer Products Customer Service Department


28209 Ave. Stanford
Valencia, CA 91355

Toll Free: (800) 423-0273


Direct : (661) 257-4411
FAX: (661) 775-1798
E-mail: warranty@answerproducts.com
tech@answerproducts.com
Web site: www.answerproducts.com

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SECTION 1: INTRODUCTION
This manual is intended to guide the user through basic service of Manitou Radium rear shocks.
Service is supported by the identification of common parts and assemblies that have been
assembled into Service Kits. The purpose of this manual will be to describe conditions that may
drive the need for service and to provide installation instructions for the kits.

Due to the time-consuming nature rear shock service, at this time our primary focus is to offer
service kits that minimiRadiume the amount of downtime and labor involved. As the program
matures, and we are able to gather feed back from our customers, we may offer kits to a more
detailed level.

GENERAL WARNING: Rear shocks by design contain gases and fluids under extreme
pressure and warnings contained in this manual must be observed to reduce the
possibility of injury or possible death. Following these instructions can help you
reduce the risk of being injured. Any questions in regards to the information in
this manual should be directed to Answer Products Customer Service at (661)
257-4411.

CAUTION: The Radium Shock uses compressed air to provide fluid pressure in the
damping system and spring resistance. These systems must be relieved of pressure prior
to servicing. Failure to relieve air pressure could result in injury or possible death.

CAUTION: The Radium Shock uses precision machined aluminum and other soft alloy
components. Using correct tools for assembly is essential to prevent damage.

SECTION 2: SETUP, TUNING, PERIODIC MAINTENANCE


Instructions for shock setup, tuning, and periodic rider maintenance is not covered in detail in this
manual. Please refer to the Manitou Radium Rear Shock Owner's Manual for that information. If
you did not receive a manual, you can download one at www.answerproducts.com or contact
Answer Products Customer Service at (661) 257-4411.

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SECTION 3: GLOSSARY OF TERMS
Air Canister Can that holds the air spring air in an air shock.

Bottom Out Point at which a shock reaches full compression.

Control Eyelet (C-End) Eyelet that is on the rebound adjuster end of a shock. The air canister
is attached to this end on air shocks.

Damper Eyelet (D-End) - Eyelet that is on the damper body end of a shock.

Damper Body Section of shock that contains the damping system

Damper Shaft Shaft attached to the damper piston that connects the two moving sections
(damping system and control eyelet) of the shock together.

Damping System - Controls compression and rebound rate (speed).

DU Bushing Teflon guide bushing pressed into the eyelets. Mounting hardware is inserted into
the DU bushings and rotates within the bushing as need by the suspension design.

Eyelet Found on each end of the shock, it is where the DU bushing and mounting hardware are
and provides the connection between the shock and bicycle.

Internal Floating Piston (IFP) - A floating piston that separates damping oil from the damping
system air chamber.

Lockout - Found on RADIUMRL shocks. The Manitou lockout significantly increases the amount
of load reRADIUMuired to compress the shock. The lockout does not prevent compression under
load, only increases the amount of load required to compress the shock.

Mounting Hardware Hardware that allows shocks to be mounted into the wide variety of
suspension designs.

Schrader, Air Black in color, it is the valve for adding or releasing pressure from the air canister
in an air shock

Seals: O-Rings - Black synthetic rubber with a round cross section. Primarily used for fluid
sealing.

Seals: Quad Seals - : Black synthetic rubber with an X cross section, primarily used for sealing
air.

Seals: Wipers Teflon ring, used for keeping debris out of quad seals, guiding the damper
piston, and providing support.

Top Out Point at which a shock returns to its full extension.

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SECTION 4: COMPLETE SHOCK LESS MOUNTING HARDWARE
The highest-level kit offered will be a complete shock without mounting hardware. These kits are
offered as a fast replacement where all that is need is to change out the hardware or damping
unit.

RADIUM Shock Less Mounting Hardware

SECTION 5: HARDWARE REMOVAL AND INSTALLATION


Mounting hardware is used to mount shocks to the various frame configurations. Over time,
hardware may wear between the mounting bolts or DU Bushing which will result in play in the
connection.

Remove hardware using pliers as shown in Figure 1 DU Bushing Eyelet

.
Figure 1 Figure 2

HARDWARE REPLACEMENT

Hardware should have a slight press fit into the DU bushing and can be tapped in place with a
rubber mallet or soft jaws in a vise. Apply a small amount of thick grease such as Motorex Bike
Grease 2000 (PN 85-0033) to the hardware before installation.

There are virtually an infinite number of hardware combinations in use on bikes today. When
ordering hardware from Answer Products, It will be necessary to identify the overall eyelet width,
eyelet width, and mounting hole diameter.

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HARDWARE REMOVAL AND INSTALLATION- (CONT.)

1. Measure the overall eyelet width. 2. Measure hole size. Current hardware
are designed to accept a 6mm or 8mm
fastener.

3. Measure eyelet width.

SECTION 6: DU BUSHING REMOVAL AND INSTALLATION


DU bushings are press fit into the shock eyelets at each end of the shock. The hardware fit into
the bushings and will rotate slightly within the bushing during suspension compression. DU
Bushings, like hardware, may wear over time. Removal and installation is accomplished using
tool PN 85-6075.

REMOVAL

1. Remove hardware from the shock.


2. Insert unthreaded end of punch into the
removal tool first and screw in about half a
turn.

Punch

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DU BUSHING REMOVAL AND INSTALLATION (CONT.)

3. Clamp removal tool in vise.


4. Insert eyelet into tool.
5. Use 6mm hex wrench to screw in punch,
making sure that it is centered on the
bushing. This will press out the bushing.

INSTALLATION

1. Place a bushing onto the threaded end of


the punch and into the removal tool; screw
in about half a turn.
Bushing

2. Clamp removal tool in vise.


3. Insert eyelet into tool.
4. Use 6mm hex wrench to screw in punch,
making sure that it is centered on the
bushing and that the bushing is centered to
the eyelet. This will press in the bushing.

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SECTION 7: AIR CANISTER
WARNING: Manitou RADIUM Air Shocks use compressed air to provide resistance to
compression in place of a coil spring. You must be certain that the air canister is relieved
of all pressure prior to servicing the air system. Failure to relieve air pressure could result
in injury or possible death.

Failure of an air shock to maintain air pressure is usually the result of defective or worn seals. If
there is suspicion of an air leak, the location can be isolated by spraying the air canister joints
with a mild solution of dish soap and water. Bubbles will form in from the area of leakage. You
can also immerse the shock in water to locate the leak.

Sealing of the shock is accomplished through a series if o-rings, RADIUMuad seals, and wipers.
When the air canister is removed, these seals can be replaced from Seal Kit C.

Seal Descriptions:

O-Rings: Black synthetic rubber with a round cross section. Used for fluid sealing.
RADIUMuad Seals: Black synthetic rubber with an X cross section, used for sealing air.
Wipers: White Teflon, used for keeping debris out of RADIUMuad seals.

1. For leaks at the adjuster eyelet or damper Adjuster Eyelet Schrader


end of the air canister, refer to the detailed
disassembly instructions below.

2. For leaks at the Schrader valve, release all


air pressure and replace the Schrader valve
core or assembly as needed.

3. If when you pressuriRadiume the air canister


the shock collapses to its shortest travel
position, the shock has an air piston leak
into the negative chamber. Place the shock
in the shock tester and extend it to its full Shock in Shortest Travel Position
travel. Depress the adjuster eyelet Schrader
while the shock is extended under load. If it
remains in the full travel position, refer to
the detailed disassembly instructions below
for instructions on servicing the air canister
and piston seals.

4. If the shock returns to the short travel


position, it is not serviceable and the entire
shock must be replaced.
Extend to long travel and depress the air
WARNING: Attempting to service a
canister Schrader Valve
shock with this condition could result in
injury or possible death.

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SECTION 8: AIR CANISTER REMOVAL AND SEAL SERVICE

1. Failure of an air shock to maintain air


pressure is usually the result of defective
or worn seals. If there is suspicion of an
air leak, pressuriRadiume the air canister
to 150psi from the adjuster eyelet
Schrader Valve. Locate the leak by
spraying the air canister and Schrader
joints with a mild solution of dish soap and
water or submerge in a bucket of water.
Bubbles will form in from the area of
leakage.

2. Release All air pressure from air canister. Air release Schrader valve
Remove hardware as shown under
HARDWARE REMOVAL AND
INSTALLATION. For leaks at the Schrader
valves, release all air pressure and replace
the Schrader valve core or assembly as
needed. The core is removed using a
standard core removal tool. The assembly
is removed by removing the core and
unscrewing the assembly by inserting a
3mm hex into the center of the valve.

3. Place adjuster eyelet in a vise using soft


jaws. Using a rubber strap wrench to
prevent damage, loosen the air canister
completely

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AIR CANISTER REMOVAL AND SEAL SERVICE (CONT.)

4. Slide air canister away from the canister Damper Cap: DO NOT REMOVE
eyelet and remove.

WARNING: Do not remove the damper cap.


The damper system is under extreme
pressure. Removal of the damper cap
without releasing damper system pressure
will result in the possibility of injury or
possible death.

5. Replace o-rings, seals, and wipers in the air


canister and air piston. Air Canister Kit A will
have new seals installed as part of the kit. Also
replace the o-ring inside the canister eyelet.

O-Ring, Seal, Wiper Locations

6. Lightly grease the air piston, damper body,


air canister seals, and inside the air canister
with a thick grease such as Motorex Bike
Grease 2000.

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AIR CANISTER REMOVAL AND SEAL SERVICE (CONT.)

7. Slide air canister over the damper body.

8. Lightly grease the air canister threads and


inside the canister. Screw the air canister
into the canister eyelet. Due to pressure in
the damping system, it may be difficult to
compress the shock enough to thread the
canister onto its eyelet. If necessary, the
shock test fixture can be used.

SECTION 9: DAMPING SYSTEM


CAUTION: The RADIUM Shock uses compressed air to provide fluid pressure in the
damping system and spring resistance. These systems must be relieved of pressure prior
to servicing. Failure to relieve air pressure could result in injury or possible death.

RADIUM Shock damping system service reRADIUMuires special tooling and training that is
unavailable at this time. In cases where it is suspected that there is air in the damper or the
damper body is leaking oil, the shock should be replaced.

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SECTION 10: RADIUM SHOCK TROUBLESHOOTING CHART

Symptom Cause Solution Service Section


Air Spring
Schrader valve Interference with Replace. Confirm 8
snapped off at base suspension linkage or clearance after
other frame Schrader replacement
components
Air loss from air spring Air spring Schrader Tighten or replace 8
valve leaks Schrader core or
replace Schrader
assembly.
Seal failure on Air Replace seal(s) 8
Canister
Seal failure on Air Replace seal(s) 8
Piston
Air shock does not Failure of negative Replace air canister 7
return to full travel but spring and seals
has adeRADIUMuate
air spring pressure
Hard top out Failure of negative Replace air canister 8
spring and seals
Hard Bottomout Air spring pressure Increase air canister 8
too low air pressure
Damping Oil Leaks
Oil leak at base of air Worn or damaged Replace shock 4
canister seals allowing oil to
escape from damper
chamber
Oil comes out of the Damping oil has Replace shock 4
Air Spring Schrader leaked past the
valve damper cap
Damping System Performance
Adjusting rebound Air in damping system Replace shock 4
knob has no effect.
Lockout does not Air in damping Replace shock 4
work system, Low IFP
pressure.
Mounting Hardware
Play in shock eyelets Worn DU bushing or Replace 5, 6
when mounted in bike mounting hardware

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SECTION 11

TABLE 1
FASTENER TORRADIUMUE RERADIUMUIREMENTS

Feature TorRADIUMue

Swinger Air
Air Canister 15 24KgCm (13 21inlbs)
Schrader Valve Stem 5 10 KgCm ( 4 to 9 inlbs)

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SECTION 12: 202005 RADIUM SHOCK SERVICE KITS

Kit Description Kit RADIUM


RADIUM RADIUMR RADIUMRL
A-410 A-420 A-430
Air Canister
Regular Mount 25mm Travel (1.00") 85-4461 85-4462
Regular Mount 32mm Travel (1.25") A 85-6035 85-4463
Regular Mount 38mm Travel (1.5") A 85-6036 85-4464
Regular Mount 50mm Travel (2.0") A 85-6037

Schrader Valves
RADIUM & RADIUMR Air Canister Schrader
Valve Assy, Black A 85-4400
RADIUMRL Air Canister Schrader Valve Assy,
Black A 85-4407

Complete Shock, Without Hardware


152mm Eye to Eye, 32mm Travel B 85-6128 85-6133 85-6140
165mm Eye to Eye, 38mm Travel B 85-6129 85-6134 85-6143
190mm Eye to Eye, 50mm Travel B 85-6131 85-6138 85-6144
200mm Eye to Eye, 50mm Travel B 85-6132 85-6139 85-6145

RADIUM Shock IFP Chamber Refill Plug B 85-5436

Seal Kit C 85-6054

Mounting Hardware Kits D (Contact Answer Products)

Hardware Bushing Kit E


DU Bushing E 85-6105

Sticker Kit F

Sticker Kit, RADIUM Shock F 85-4402


Sticker Kit, RADIUMR Shock F 85-4403
Sticker Kit, RADIUMRL F 85-442005
Sticker Kit, RADIUM, RADIUMR, RADIUMRL
Trunion Shock F 85-4405

Tools H
DU Bushing Tool H 85-6075
Fixture to Hold and Compress Shocks H 85-3008
Shock Pump - Air Canister H 85-4069

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202005 RADIUM REAR SHOCK SERVICE KITS - DESCRIPTION

A - Air Canister B - RADIUM Shock, No Hardware

C - Seal Kit

D - Hardware E - DU Bushing Kit

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F - Sticker Kit H - DU Bushing Tool

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